Lights Out: Technology and Automation Podcast by MakingChips

What does automation actually look like when you're in the middle of it—not from a vendor demo or a conference stage, but inside a real shop, with real constraints, real people, and real stakes? This episode of Lights Out kicks off a new series format—Lights Out Lenses—where the story of automation is told through multiple perspectives inside the same company. And not just any company, but ADVANCED MACHINING & FABRICATING Dba ADVANCED PMC, a shop that's deep in the trenches of high-mix, low-volume manufacturing. Instead of a single narrative, you'll hear how automation is experienced differently depending on where you sit. From the Director of Operations thinking about material flow and process alignment, to the Director of Production obsessing over utilization and throughput, this episode pulls back the curtain on what it really takes to make automation work—not just in theory, but in practice. Randel Hamilton shares how automation didn't simplify the business—it expanded it. More output meant more coordination, more downstream pressure, and more need for structure. The machine might run lights out, but everything around it has to keep up. Meanwhile, PK brings a numbers-driven lens, breaking down the hidden opportunity in unused machine hours and why automation is less about technology and more about stability, repeatability, and smart part selection. Together, their perspectives reveal a powerful truth: automation doesn't eliminate complexity—it redistributes it. And for shops willing to embrace that shift, the payoff isn't just more parts—it's a fundamentally different way of thinking about the business.  You will want to hear this episode if you are interested in... (0:00) Lights Out Lenses: exploring automation through multiple perspectives (2:21) Randel Hamilton's background and early exposure to automation (4:29) The reality of automation implementation: years of iteration, not plug-and-play (6:46) Common misconceptions about automation and the importance of building the system while running it (8:22) How automation impacts jobs: shifting roles rather than eliminating them (10:33) Deciding what should and shouldn't be automated in a real-world shop (12:19) Why we love SMW Autoblok workholding and its effectiveness (15:00) Business impact: automation driving new responsibilities in sales, purchasing, and capacity planning (17:59) Personal impact: improved scheduling, reduced overtime pressure, and process-driven operations (22:06) Randel reflects on stress levels before and after automation (23:40) Get a free report of sales opportunities in your area from Facturmfg.com/chips (25:37) PK's role and focus on execution, output, and maximizing existing equipment (27:57) Overview of the FASTEMS automation cell and current utilization gap (29:14) The opportunity: capturing unused machine hours and increasing throughput (32:23) Key challenges including part selection, high-mix/low-volume work, and tight tolerances (33:56) Why we created Hire MFG Leaders (and why you should use it)  (34:30) How production teams evaluate which parts are good candidates for automation (35:49) The complexity of scheduling, tooling, workholding, and keeping the cell running (38:47) Continuous improvement mindset: expanding automation across more machines and processes (42:08) Using data and metrics to drive better performance and decision-making (43:43) PK reflects on stress levels and ongoing challenges in production (45:22) Key takeaway: automation shifts work, requires stability, and unlocks new levels of performance Resources & People Mentioned Why we love SMW Autoblok workholding and its effectiveness Get a free report of sales opportunities in your area from Facturmfg.com/chips Why we created Hire MFG Leaders (and why you should use it)  Connect with ADVANCED MACHINING & FABRICATING Dba ADVANCED PMC DVANCED MACHINING & FABRICATING Dba ADVANCED PMC Randel Hamilton on LinkedIn Connect with PK (Pankaj Khanal) on LinkedIn Connect With Lights Out LinkedIn MakingChips.com Subscribe to Lights Out On Apple and Spotify

Automation has a reputation problem. It's often painted as something reserved for massive factories, predictable part runs, and deep pockets. But what happens when a small, high-mix shop decides to challenge every one of those assumptions—and wins? In this episode of Lights Out, we sit down with Katie Murphy from Arcamed, an 80-person medical manufacturing company that did what most shops think is impossible: they built a fully functional, high-mix automation system… themselves. No massive integrator contracts. No perfect production environment. Just curiosity, grit, and a willingness to figure it out as they went. Katie walks us through how their team tackled one of the toughest use cases for automation—low volume, constantly changing parts—and still managed to unlock serious gains in machine utilization, throughput, and employee growth. From a "hokey bookshelf" prototype to a system capable of running 50+ hours unattended, this is a masterclass in progress over perfection. But this isn't just a story about robots. It's about mindset. It's about rethinking what your people should be doing, where your real bottlenecks are, and how much hidden capacity is sitting idle in your shop right now. The result? More output, higher wages, and a team that's more engaged than ever. If you've ever said, "automation won't work here," this episode might just change your mind. You will want to hear this episode if you are interested in... (0:00) Busting automation myths: small shops, high-mix work, and non-standard materials (1:57) Introducing Katie Murphy and the Arcamed automation journey (5:41) Inside Arcamed: medical manufacturing, machining plastics, and fabrication (9:07) The real problem: high-mix, low-volume production bottlenecks (11:21) Katie's role in continuous improvement and hands-on automation development (13:24) The goal: increasing machine utilization without adding labor (14:48) Why you need to look into grants for your businesses (16:28) Head to the DN Solutions Manufacturing Without Limits event (17:31) Measuring success through unattended runtime and capacity gains (21:52) Avoiding "local optimization" and freeing operators to do higher-value work (24:56) Upskilling employees and increasing wages through automation (26:42) Why Arcamed chose DIY automation over turnkey systems (29:06) From prototype "bookshelf" to scalable automation cell design (31:22) Using common features (like vises) to automate diverse part geometries (34:00) Get a free report of opportunities in your industry from FacturMFG.com/chips (35:08) The iterative process: trial, error, and continuous improvement (37:21) Learning automation skills on the job through problem-solving (42:15) The impact: major gains in spindle utilization and overall capacity (44:16) Investing in ProShop ERP is an investment in your shop (45:55) What's next: scaling systems and expanding press brake automation (47:37) The future: AI, vision systems, and bin picking capabilities (49:40) Advice for shops: the 80/20 rule and avoiding perfection paralysis (52:21) Arcamed's plans for learning at IMTS 2026 Resources & People Mentioned Conexus Indiana Head to the DN Solutions Manufacturing Without Limits event Get a free report of opportunities in your industry from FacturMFG.com/chips Investing in ProShop ERP is an investment in your shop IMTS 2026 Connect with Katie Murphy Arcamed Connect on LinkedIn Connect With Lights Out LinkedIn MakingChips.com Subscribe to Lights Out On Apple and Spotify

What happens when a shop that's already running lights-out decides to push even further? The Lights Out team returns to Imago Manufacturing nearly a year after their first visit to see how Ryan's lights-out vision has evolved. What they find is a shop that looks similar on the surface, same team, same footprint, but dramatically more capable thanks to thoughtful automation, improved workflows, and a relentless focus on unlocking unused capacity. It's a real-world look at what continuous improvement actually looks like in a small, highly automated shop. Ryan shares how Imago is pushing toward an ambitious goal: grow revenue by 50 percent over three years without adding people, spindles, or floor space. That challenge forces a different mindset, one centered on maximizing throughput, eliminating wasted motion, and using automation not just at night, but throughout the workday. The conversation explores how new robot loading, automated inspection, and smarter quoting strategies are helping the team move closer to that target. Beyond the technical strategies, the episode dives into the philosophy behind lights-out machining. Ryan explains how automation improves quality of life, removes repetitive work, and allows machinists to focus on higher-value problem solving. The group also introduces the concept of "lights in" manufacturing, automating processes during the day to create more freedom, focus, and productivity while the team is in the building. This return visit to Imago blends practical automation insights with a bigger message: lights-out isn't just about running machines unattended. It's about building a shop that respects people's time, increases capability without increasing headcount, and creates the kind of flexibility that makes both the business and the people inside it stronger.  You will want to hear this episode if you are interested in... (0:00) Cigar, bourbon jokes, and setting the stage for a return visit to Imago (2:47) Introduction to Imago Manufacturing and recap of the first Lights Out episode (5:05) What's changed in a year and continuing the lights-out vision (6:59) Same team, more automation, and a thriving shop culture (8:41) Why you need to check out the Hennig WorkFlow system (9:34) New robot loader and instant buy-in from the team (12:03) Respecting machinists' time and eliminating repetitive work (14:45) Parenting advice, focus, and the philosophy behind time freedom (18:07) Automation as a path to better quality of life (20:32) SMW Autoblok offers world-class workholding (21:51) New mill automation and flexible vise-based workflow (26:57) Using automation as a competitive quoting advantage (30:12) The 50 percent growth goal and finding hidden capacity (37:28) Automating inspection and the ROI of measurement time (42:56) Head to the DN Solutions Manufacturing Without Limits Event (43:57) Introducing "lights in" manufacturing Resources & People Mentioned The Key to Time Freedom in Machining The Juice to Squeeze Ratio Imago Manufacturing Daily Lights Out Checklist Why you need to check out the Hennig WorkFlow system SMW Autoblok offers world-class workholding AI5X Smart Assistant by Intelligent Automation Head to the DN Solutions Manufacturing Without Limits Event The Goal Connect with Ryan Bankel Imago Manufacturing  Imago Manufacturing on Instagram Connect with Ryan on LinkedIn Connect With Lights Out LinkedIn MakingChips.com Subscribe to Lights Out On Apple and Spotify

Additive manufacturing has been "the future" of manufacturing for decades. And yet, for many shops, it still feels just out of reach—either too expensive, too complex, or too uncertain to justify. So where does it actually stand today? In this episode of Lights Out, we sit down with Mark Barfoot, VP of Global Sales at Xact Metal, to cut through the noise. With more than two decades of experience in additive, Mark has seen the technology evolve from experimental curiosity to a legitimate production tool—and he brings a grounded, shop-floor perspective on what's real versus what's hype. We explore where additive is delivering real value right now, starting with jigs, fixtures, and tooling, and how shops are using those applications as a gateway into more advanced production parts. Along the way, we unpack the biggest misconceptions—especially the idea that additive is simply a cheaper way to make the same parts—and why success starts with designing for the technology, not forcing it into existing workflows. The conversation also dives into what it actually takes to bring metal additive into a machine shop—from facility requirements and safety considerations to the learning curve your team should expect. If you've ever wondered whether additive belongs in your shop (or how to even begin evaluating it), this episode gives you a clear, practical starting point. Because the real question isn't whether additive will replace traditional machining—it's where the two work better together.  You will want to hear this episode if you are interested in... (0:00) Real-world additive use cases including jigs, fixtures, and lightweight tooling (2:19) Introducing Mark Barfoot and the current state of metal additive manufacturing (6:54) Understanding additive hype cycles and why adoption takes time (11:23) Why we created Hire MFG Leaders (and why you should use it) (11:53) Why additive sticks: design freedom and enabling impossible geometries (14:31) Designing for additive vs trying to replace traditional machining (16:13) Where additive technology stands today across plastics and metals (19:51) Production applications and additive adoption in job shops (22:53) Justifying additive versus subtractive manufacturing  (24:35) An investment in ProShop ERP is an investment in your business (26:10) Facility requirements for bringing metal additive into a machine shop (32:45) Come see us at IMTS 2026! (33:39) Resources that shop owners should dig into to learn more (35:19) Common misconceptions about additive cost and capabilities (38:09) How AI and topology optimization are shaping additive design (41:57) Practical ways shops can start using additive internally (46:04) Training, education, and building additive expertise in-house (49:23) When additive makes sense and how shops should evaluate adoption Resources & People Mentioned Why we created Hire MFG Leaders (and why you should use it) An investment in ProShop ERP is an investment in your business Come see us at IMTS 2026! Connect with Mark Barfoot  Xactmetal.com [email protected] Connect With Lights Out LinkedIn MakingChips.com Subscribe to Lights Out On Apple and Spotify

What happens when you take months of serious conversations about automation ROI, additive manufacturing, machine monitoring, adaptive controls, and digital factory strategy… and turn them into Jeopardy? Chaos. Competitive chaos. In this special episode of Lights Out, Eric Nekich steps into full game-show-host mode and challenges Dave Vuyk, Nick Goellner, and special guest Mike Payne to prove they've actually been paying attention to everything the show has covered recently. The result is part recap, part rivalry, and part unhinged manufacturing trivia night. The categories pull directly from some of the biggest themes the show has explored lately: machine tool monitoring, automation, adaptive control, additive manufacturing, CNC myths and stereotypes, and digital factory tech. Along the way, the group revisits ideas around hybrid manufacturing, predictive maintenance, collaborative automation, and why modern machinists are far more than button pushers. But this episode is more than a gag. It's a fun, fast-moving summary of the real lessons behind recent Lights Out conversations. Underneath the jokes, arguments, and questionable Jeopardy rulings is a sharp reminder that the future of manufacturing belongs to shops willing to learn, adapt, and apply technology with intention. And yes, in true Jeopardy fashion, wrong answers cost money. Which makes the final scoreboard even more entertaining. You will want to hear this episode if you are interested in... (0:00) Welcome to the first episode of Lights Out Jeopardy (2:51) The game board: six categories covering automation, additive, monitoring, and digital factory tech (3:26) The first round begins with CNC myths, machine monitoring, and predictive maintenance (6:51) Additive manufacturing trivia: hybrid manufacturing and common misconceptions (10:28) Unlock Real Sales Opportunities in Your Market: Get a free report at facturmfg.com/chips (11:36) Daily Double: the biggest barrier to automation (13:44) Adaptive control, tool breakage prevention, and the economics of smart machining (16:43) What actually makes a smart factory "smart?" Data, reporting, and decision-making (19:05) Why you need to come to IMTS 2026 (20:03) ERP systems, Industry 4.0, and machine-to-machine communication (24:46) Lights-out manufacturing: what robots really replace in the shop (29:30) Machine monitoring myths: helping machinists instead of replacing them (33:02) Manufacturing myths, modern shops, and the "tech lab" reality of today's factories (39:30) Why we love SMW Autoblok for workholding (40:20) Adaptive machining explained using cruise control (43:58) Machine monitoring alerts, efficiency, and reducing unplanned downtime (47:25) Final round chaos: aerospace, robots, and a bottom-row Jeopardy sweep (50:44) The winner is revealed… Resources Mentioned  Unlock Real Sales Opportunities in Your Market: Get a free report of at facturmfg.com/chips IMTS 2026 SMW Autoblok Connect With Lights Out LinkedIn MakingChips.com Subscribe to Lights Out On Apple and Spotify

There's been a murder on the shop floor. Or at least… that's how this episode begins. In this creative, detective-themed installment of Lights Out, Dave Vuyk, Eric Nekich, and Nick Goellner investigate what happened to the once red-hot promise of collaborative robots. A decade ago, cobots were projected to revolutionize machine shops. They were marketed as affordable, easy-to-deploy, cage-free automation that would solve the labor crisis and democratize robotics for small and mid-sized manufacturers. But the explosive growth forecasts never quite materialized. So what happened? Was it marketing overpromise? Technical limitations? Payload constraints? Misapplication? Integration complexity? Market saturation? Or was the industry simply expecting too much, too fast? The verdict might surprise you.  This episode blends humor, hard-earned lessons, and practical automation strategy to unpack what actually works — and what doesn't — when bringing robotics onto the shop floor.  You will want to hear this episode if you are interested in... (1:00) The "murder mystery" setup: Who killed the cobot dream? (4:04) The golden age of cobot hype and early trade show buzz (5:03) Democratizing automation: what cobots promised (8:08) The speed problem: why machinists called them "too slow" (11:40) The payload limitation reality in CNC applications (9:42) Join us at the 2026 MFG Meeting (13:37) Reliability and durability concerns on real shop floors (15:31) Suspect #1: Marketing overpromise (15:55) Suspect #2: Technical limitations (speed, strength, communication) (17:16) Suspect #3: Misapplication (20:26) Suspect #4: Integration complexity in imperfect environments (22:51) Suspect #5: Market saturation and low-cost competitors (25:50) The plot twist: The dream didn't die (19:13) Why you should check out the SMW Autoblok catalog (27:13) Why ISO and ANSI eliminated the term "cobot" in 2025 (29:11) Application-specific risk assessments and safety standards (31:19) When collaborative applications make sense (budget, space, repetition) (39:36) Get a free report of opportunities in your industry from Factormfg.com/chips (34:16) Real-world success story: medical plastics and lightweight parts (36:23) Final verdict: The right automation is the one that actually works Resources & People Mentioned Join us at the 2026 MFG Meeting, March 10th-12th in Ft. Lauderdale, FL Why you should check out the SMW Autoblok catalog Get a free report of opportunities in your industry from Facturmfg.com/chips Connect With Lights Out LinkedIn MakingChips.com Subscribe to Lights Out On Apple and Spotify

Is hybrid manufacturing just a buzzword, or is it the next logical evolution of modern machining? In this episode of Lights Out, David Vuyk, Nick Goellner, and Eric Nekich sit down with Dr. Jason Jones, CEO and founder of Hybrid Manufacturing Technologies, to unpack what hybrid manufacturing actually means and why it's gaining real traction inside production environments. Rather than framing additive and subtractive manufacturing as competing technologies, Dr. Jones explains how the real opportunity lies in integrating them. By combining metal 3D printing, CNC machining, and in-process inspection into a single digitally controlled workflow, manufacturers can dramatically reduce wasted motion, eliminate handoffs, and unlock new efficiencies, especially in repair, feature addition, and late-stage configuration. The conversation goes beyond hype. The hosts dig into practical applications, certification challenges, inspection integration, ROI expectations, and what's truly holding shops back from adopting hybrid systems. For shops looking to modernize without blindly chasing the newest trend, this episode offers a grounded look at where hybrid fits into a broader automation strategy. You'll want to hear this episode if you are interested in... (0:15) Mark your calendars and join at IMTS 2026 (3:17) Introducing Dr. Jason Jones and Hybrid Manufacturing Technologies (5:36) What hybrid manufacturing is (and how it will impact the industry) (9:32) Dr. Jones' journey from machinist to hybrid pioneer (16:10) Why hybrid manufacturing is often misunderstood (18:52) The false "additive vs. subtractive" debate (21:02) Real-world hybrid applications happening today (26:37) Why quality validation is the biggest adoption barrier (29:42) Blade repair and aerospace up-revision case study (32:28) Large-scale additive and gantry-style systems (35:00) Investing in ProShop ERP is an investment in your shop? (36:35) The chicken-and-egg problem with design adoption (39:52) Hybrid manufacturing and Industry 4.0 (43:57) Integrating in-process inspection (ultrasound, eddy current, etc.) (46:39) Adoption trends: early adopters vs. practical majority (49:40) Typical cost ranges for hybrid implementation (54:47) Why partnership matters in implementation (58:37) Practical advice for shops evaluating hybrid manufacturing (1:02:39) Why we created Hire MFG Leaders (and why you should use it) Resources & People Mentioned Mark your calendars and join at IMTS 2026 Investing in ProShop ERP is an investment in your shop Hire MFG Leaders Connect with Dr. Jason Jones Hybrid Manufacturing Technologies Connect on LinkedIn Connect With Lights Out LinkedIn MakingChips.com Subscribe to Lights Out On Apple and Spotify

What does the future of manufacturing look like when it's built by someone who has never known a world without digital tools, automation, or on-demand learning? In this episode of Lights Out, the hosts sit down with Michael King, founder of Munkworks, whose story feels almost implausible until you hear it unfold. Michael bought his first CNC machine as a teenager, owns a five-axis machining center before he's old enough to legally drink, and runs a growing shop almost entirely on his own. But this conversation isn't about novelty. It's about mindset. From early hands-on building and 3D printing to running production parts lights-out overnight, Michael's approach challenges long-held assumptions about experience, labor, and scale in manufacturing. The discussion traces his unconventional path from RC airplanes and additive manufacturing into full-scale CNC machining, contract manufacturing, and automation. Along the way, the hosts explore how content, curiosity, and community replaced traditional apprenticeships, and why automation was never an afterthought for Michael, but the starting point. More than a technical discussion, this episode is a reflection on priorities. Michael is building a business designed around time freedom, family, and stewardship, not just output. It's a candid look at how the next generation may redefine what a successful machine shop looks like, and why lights-out manufacturing often starts with intention, not robots. You will want to hear this episode if you are interested in... (0:00) A 20-year-old shop owner with a five-axis machine (1:02) Meeting Michael King and why his story stands out (3:47) Early curiosity, hands-on building, and RC airplanes (5:09) Running a 3D printer "farm" as a teenager (7:47) COVID-era projects and leading hardware development (9:26) Moving from additive into subtractive manufacturing (10:47) Growth isn't accidental—it's engineered by Factur  (12:15) Discovering machining through YouTube and Titans of CNC (15:10) Balancing entrepreneurship, faith, and young family life (18:32) How contract work funded product innovation (22:37) Why automation was necessary, not optional (24:14) Choosing a five-axis machine without a pallet pool (25:16) Register for IMTS 2026 - we'll see you there! (27:24) A generational shift in how shops think about automation (30:07) First real "lights-out" win on the lathe (33:18) Designing a business around family time (35:04) Goals for scaling automation in 2026 (42:29) Moving a semi-trailer from Tennessee to Idaho (43:23) Surviving difficult moments as a young entrepreneur (47:33) Practical advice for automating without big capital expense (51:45) Why we love SMW Autoblok workholding Resources & People Mentioned Get a free report of opportunities in your industry from facturmfg.com/chips  Get your workholding from SMW Autoblok  Register for IMTS 2026 - we'll see you there! Within Tolerance podcast Connect with Michael King Connect on LinkedIn Munkworks Connect With Lights Out LinkedIn MakingChips.com Subscribe to Lights Out On Apple and Spotify Audio Production and Show Notes by - PODCAST FAST TRACK

Automation doesn't end when the system is powered on. In fact, that's often where the real work begins. In the third and final episode of this Lights Out series, the conversation shifts from planning and justification to execution, measurement, and long-term performance. After covering market forces driving automation adoption and breaking down ROI math in the first two episodes, this installment tackles the question many shop owners wrestle with once automation is live: Is this actually working? Dave Vuyk and Eric Nekich dig into how to validate performance, track meaningful metrics, and avoid leaving ROI on the table after implementation. Rather than chasing dozens of KPIs, the discussion focuses on practical measurement frameworks that connect directly back to the original business problem automation was meant to solve. From labor efficiency and throughput to OEE and cost per unit, the hosts explain how to create visibility without overwhelming leadership or alienating the shop floor. This episode also explores the human side of post-automation success. Metrics aren't meant to be surveillance tools. When used correctly, they become shared scorecards that drive engagement, continuous improvement, and ownership across the organization. For shops serious about lights-out manufacturing, this final chapter reinforces a simple truth: automation only delivers value when outcomes are measured, understood, and continuously improved. You will want to hear this episode if you are interested in... (0:00) Recap of the three-part automation ROI series (2:03) The risk of flying blind without a measurement framework (3:20) Why tracking everything dilutes ROI visibility (3:58) Tying KPIs back to the original business problem (4:46) Core automation KPIs tied to ROI calculations (6:08) What realistic ROI looks like 90 days after implementation (6:45) Join us at the 2026 IMTS Exhibitor Workshop (8:52) Why labor savings alone don't tell the full story (10:55) Manufacturing cost as a percentage of revenue (11:44) Translating KPIs into shop-floor language (12:50) Capacity gains, lead times, and customer impact (13:39) Breaking down OEE into availability, performance, and quality (16:36) How fixturing and workholding affect automation ROI (18:46) Process reliability, chip management, and coolant considerations (20:06) Why ROI ownership must extend beyond leadership (21:22) Why we love SMW Autoblok for workholding (22:33) Benchmarking without falling into the comparison trap (25:36) Industry averages for OEE, OTD, and cycle time reduction (27:40) Crawl, walk, run expectations for lights-out automation (29:52) Change management and shop-floor buy-in (34:24) Three post-implementation actions to lock in ROI (38:56) Use Hire MFG Leaders for your next hire Resources & People Mentioned Join us at the 2026 IMTS Exhibitor Workshop Check out SMW Autoblok's catalog ProShop ERP Connect With Lights Out LinkedIn MakingChips.com Subscribe to Lights Out On Apple and Spotify Audio Production by - PODCAST FAST TRACK

Automation is exploding across the manufacturing world, but the real differentiator isn't the robot, pallet pool, or software you buy—it's whether you know how to calculate ROI the right way. In this episode of Lights Out, we break down the financial side of automation in plain language so every shop owner, operator, and leader can make smarter investment decisions with confidence. This is the follow-up to our baseline episode, where we had listeners identify their current spindle utilization, setup times, labor load, and cost per part. Now we take the next step: turning those numbers into an ROI model that actually reflects how automation performs on the shop floor. Instead of guesswork, gut instinct, or "we tried that once," we show you how to quantify annual savings, increased capacity, reduced scrap, payback period, and more. We simplify the math in a way that works for high-mix job shops, multi-shift production cells, and every workflow in between. Whether you're evaluating a robotic tending system, a pallet pool, high-density workholding, or a Cobot, understanding the financial impact of your decision is the foundation for long-term, scalable automation success. With real scenarios, honest discussion, and a few holiday-season laughs (including Nick's mysterious disappearance), this episode gives you the practical tools you need to approach automation with clarity—not confusion. If you want to make 2026 your most efficient year yet, start by calculating ROI the right way You will want to hear this episode if you are interested in... (0:23) How ProShop ERP delivered rapid ROI in Mike Payne's shop (2:49) Today's focus on ROI and key metrics (4:15) Review of required baseline data including utilization, setup time, labor load, and cost per part (6:32) Breakdown of the simple ROI formula and the more detailed expanded formula (8:53) ROI Example: Labor savings, increased spindle hours, and scrap reduction (12:39) Method for calculating labor savings using remaining labor percentage (13:45) Why you should use Hire MFG Leaders for your next hire (14:16) Converting increased machine utilization into measurable financial value (15:02) Impact of pallet pools and high-density workholding on cutting setup and changeover time (16:49) Importance of including maintenance, programming, and depreciation in ROI models (19:38) Role of adaptive feed-rate controls in improving uptime and process reliability (21:57) ROI scenarios for robotic tending cells and five-axis pallet pool systems (24:18) Value of redeploying skilled operators to higher-impact work as part of automation ROI (25:16) When Cobots are an appropriate automation choice and when integrators are necessary (27:18) Key homework steps: running a basic ROI estimate and identifying utilization gaps (29:32) Why you need to check out the SMW Autoblok catalog Resources & People Mentioned How ProShop ERP delivered rapid ROI in Mike Payne's shop Why you should use Hire MFG Leaders for your next hire Why you need to check out the SMW Autoblok catalog The Core ROI Formula for Automation Simple version: ROI (%) = (Annual Savings – Annual Costs) ÷ Investment × 100 Expanded version for manufacturing: ROI = [(Labor Savings + Increased Machine Utilization + Scrap Reduction + Overtime Avoided) – Maintenance & Depreciation] ÷ Capital Cost Connect With Lights Out LinkedIn MakingChips.com Subscribe to Lights Out On Apple and Spotify Audio Production and Show Notes by - PODCAST FAST TRACK

Before a shop can automate confidently, it has to understand one thing clearly: ROI drives every great automation decision. In this episode of Lights Out, David Vuyk and Eric Nekich kick off a multi-part series on Automation ROI—focusing not on hype or shiny tech, but on the real metrics and methods that determine whether automation will pay off or become an expensive paperweight. With "Jolly St. Nick Goellner" out preparing for the holiday season, David and Eric take the mic to break down a critical truth: you cannot automate an unreliable process, and far too many shops are buying robots before they fix the fundamentals. From workholding to setup reduction to operator loading, the guys lay out the baseline measurements every shop must capture before investing in automation. They also explore why automation adoption surged 30% this year and how reshoring, labor shortages, and rising demand are pushing shops to think differently about their processes. But enthusiasm alone isn't enough—what separates successful adopters from fence-sitters is the ability to quantify ROI quickly and accurately, not in a vacuum, but across the entire upstream-downstream workflow. This episode serves as the foundation for the ROI model the hosts will build in Part 2. You'll walk away knowing which numbers matter, how to capture them (even with pen and paper), and how to prepare your shop for real automation readiness. And yes…you'll also get your homework.  You will want to hear this episode if you are interested in... (0:00) Why automation fails when processes and fixturing are unreliable (0:12) Why we love SMW Autoblok for workholding (2:18) Launching the Automation ROI series and framing the conversation (3:42) Industry trends driving a 30% rise in automation adoption (6:31) Fence-sitters, misconceptions, and why ROI must lead decisions (7:29) Step one of ROI: defining the process and the goal behind automation (11:03) Why ROI must include upstream and downstream impacts (13:46) Common automation failures, cobot misuse, and "coat hanger" systems (16:44) Core ROI foundations and costs affected by automation (17:43) Partner with Verdant Commercial Capital for financing (22:35) Metric #1: Measuring spindle utilization accurately (25:22) Metric #2: Understanding setup time and the role of modular workholding (28:50) Metric #3: Operators per machine and multi-machine tending (31:18) Metric #4: Labor cost per part and machine burden calculations (32:18) Metric #5: Remaining Labor Percentage and what "good" looks like (35:34) Homework: identify bottlenecks and capture current-state metrics (38:14) Make your next hire with Hire MFG Leaders Resources & People Mentioned Why we love SMW Autoblok for workholding Partner with Verdant Commercial Capital for financing Make your next hire with Hire MFG Leaders Connect With Lights Out LinkedIn MakingChips.com Subscribe to Lights Out On Apple and Spotify Audio Production and Show Notes by - PODCAST FAST TRACK

As we dive into this episode of Lights Out, we sit down with someone who's seen automation evolve from pencil drawings and flame-cut templates to fully integrated robotic systems: our friend and longtime industry leader, Mike Gamache. For decades, Mike has lived at the intersection of machining, fabrication, automation, and continuous improvement, and we couldn't be more excited to bring his experience to our listeners. We reflect on how we first met Mike—a mix of Germany trips, delayed flights, Delta drink tickets, and a little tough love that eventually turned into friendship and collaboration. But what really makes this conversation valuable is the unfiltered truth Mike brings about automation. We explore what makes it succeed, why it fails, and how shops can avoid the painful mistakes that come from chasing trends instead of defining real problems. Throughout our conversation, we pull back the curtain on how companies like Metalcraft of Mayville use automation to transform throughput, stabilize processes, and eliminate the dirty, dull, dangerous, and demanding work no one wants. Mike walks us through identifying bottlenecks, understanding ROI, choosing between prefab and custom solutions, and overcoming the cultural resistance that keeps shops stuck in the past. We also talk about the mindset behind automation—how lean thinking, stable processes, and leadership alignment create the foundation for truly running lights out. And in a powerful shift, we explore Mike's "Create Holy Moments" philosophy, a reminder that continuous improvement isn't just for machines—it's for people, teams, and communities as well. This episode blends humor, hard-earned wisdom, and practical guidance you can use right away. If you're serious about improving your shop and moving toward lights-out operations, this is one conversation you don't want to miss. You will want to hear this episode if you are interested in... (0:22) Partner with Verdant Commercial Capital for a smooth process (1:53) Introducing Mike Gamache (and how Eric met him) (7:24) Mike's manufacturing and engineering origins (11:07) Growing value-added steel work and machine shops (13:38) Cornerstone Design: sales, marketing, and leadership (16:44) Starting Gamache Systems and eventual acquisition by Metalcraft (18:08) Overview of Metalcraft's automation investment and Skag product line (20:10) How ROI is measured and how projects are selected (21:27) Case studies: rearranging facilities and implementing robotic processes (23:12) What shops should automate first (and why processes must be stable beforehand) (26:24) Check out the SMW Autoblok catalog (27:40) How to prioritize automation (start at shipping, work upstream) (29:36) Common blockers: legacy thinking, unclear processes, poor flow (31:14) Value of fresh eyes and cross-industry solutions (33:13) Lean foundations as a prerequisite for automation success (34:05) Strategic conviction vs short-term ROI thinking (37:30) Fear of automation and overcoming failed attempts (39:18) Leadership alignment as the key to adoption (40:42) Global competition and why automation is mandatory (44:06) Custom vs prefabricated automation: when to choose each (48:50) Sticker shock, engineering hours, and ROI evaluation (49:58) Mike's "Create Holy Moments" movement (57:58) Mike's five-step process for improvement (1:01:36) Why you need to listen to Machine Shop Mastery Resources & People Mentioned Partner with Verdant Commercial Capital for a smooth process Check out the SMW Autoblok catalog The Biggest Lie in the History of Christianity The Toyota Way Connect with Mike Gamache Metalcraft Automation Group Connect on LinkedIn Connect With Lights Out LinkedIn MakingChips.com Subscribe to Lights Out On Apple and Spotify Audio Production and Show Notes by - PODCAST FAST TRACK

What do law enforcement, SWAT operations, and CNC machining have in common? More than you'd think. In this episode of Lights Out, hosts Nick Goellner, Eric Nekich, and Dave Vuyk welcome Johnny Goode, President and Co-owner of MSP Manufacturing in Bloomington, Indiana—a precision aerospace manufacturer that's rapidly transforming its operations with automation and digital processes. Johnny's journey is anything but typical. From police officer and SWAT team member to Army National Guard sergeant, his story is packed with grit, discipline, and leadership under pressure. When he traded in his badge for a badge of a different kind—the MSP logo—he brought with him the tactical mindset and resilience that now define his company's culture and growth. Today, MSP is running 24/5, leveraging modular workholding, five-axis machining, and ProShop ERP to deliver quality aerospace parts on time, every time. In this conversation, Johnny opens up about the leadership lessons he carried from the field to the factory floor, how he earned the trust of veteran machinists, and why he believes that culture, values, and integrity are the real foundation for successful automation. From implementing five-axis technology to reducing stress on his shop floor, Johnny proves that the human element still drives even the most automated operations. If you've ever wondered what it takes to modernize a legacy manufacturer without losing its soul—or how to build trust and innovation into every shift—this episode is one you won't forget. You will want to hear this episode if you are interested in… (0:22) Achieve on-time delivery with ProShop ERP (2:13) Johnny Goode of MSP Manufacturing's origin story (6:00) Life on the SWAT team: Lessons in pressure, discipline, and adaptability (11:15) How law enforcement and military experiences shaped Johnny's leadership style (14:24) Early challenges as a next-generation leader and implementing a new ERP system (18:27) Lessons from crisis: How COVID forced diversification and sparked innovation (20:13) Enter automation: Partnering with consultants and leveraging state grants (23:14) Get a true partner in your corner with Verdant Commercial Capital  (25:00) Overcoming obstacles in automation and standardizing for success (27:38) Shop floor efficiency: 5S, tool management, and the value of observation (31:51) MSP's core values: Integrity, efficiency, resilience, precision, respect, and innovation (36:30) Managing change and getting buy-in from the team (38:03) Tracking progress: Using ProShop ERP for traceability, scheduling, and visibility (42:36) The next frontier: Expanding capacity and eliminating new bottlenecks (45:30) Balancing growth with sustainability and employee well-being (49:02) Lessons learned and what Johnny would (and wouldn't) do differently (53:33) Closing reflections and takeaway for manufacturers ready to evolve (55:40) Why you need to check out Hire MFG Leaders for your next hire Resources & People Mentioned Achieve on-time delivery with ProShop ERP Get a true partner in your corner with Verdant Commercial Capital  Why you need to check out Hire MFG Leaders for your next hire Connect with Johnny Goode Connect on LinkedIn MSP Manufacturing  Connect With Lights Out LinkedIn MakingChips.com Subscribe to Lights Out On Apple and Spotify Audio Production and Show Notes by - PODCAST FAST TRACK

In this episode of Lights Out, we debrief from one of the largest manufacturing technology shows in the world—EMO Hannover. From automation and adaptive controls to AI-driven machining and the evolving economics of shop ownership, the team unpacks what's really changing in manufacturing and what's just noise. As the hosts reflect on trends like the shift from horizontal to 5-axis machining centers, the rise of machine monitoring and IoT integrations, and the reality of underused OEM technology, they dig into what these patterns mean for modern shops aiming to run smarter—not just harder. The conversation covers more than just new gadgets on the trade-show floor—it's about how cultural adoption, change management, and continuous improvement determine whether those technologies actually deliver ROI.  We explore the parallels between software as a service and machine tool ownership models, the challenge of aligning shop-floor teams around innovation, and why data-driven manufacturing will define the next generation of top shops. Whether you're a shop owner wondering which investments will truly pay off, or a manufacturing leader preparing your business for the next wave of automation, this episode offers practical insights drawn straight from the global stage.  You will want to hear this episode if you are interested in... (0:22) Achieve RASRAM with SMW Autoblok  (1:58) IMTS vs. EMO: Comparing global manufacturing events (6:52) Eric's three major takeaways from EMO (8:23) What's driving the shift from Horizontal to 5-axis? (10:10) The acquisition of Heller (and what it signals about market dynamics) (11:52) Why one-and-done machining is critical in today's talent-scarce environment (14:30) OEM strategy shift: Removing underused tech to lower sticker prices (16:00) Adoption gaps: Why built-in monitoring often goes unused (18:16) Investing in your business is an investment in ProShop ERP (19:52) Lessons from CRM and SaaS adoption (22:05) How technology should be offered and priced to match real shop behavior (25:18) The argument for offering advanced tech as optional—not standard—to increase real adoption (26:18) Lights-Out intermission: Eric's unexpected award-winning hobby (28:56) Monitoring explosion: Using data to drive continuous improvement (32:40) The case for hiring a dedicated integrator or continuous improvement lead in every modern shop (36:27) Why offering monitoring and condition-control tools lowers risk and improves adoption (39:30) Debating whether machine builders are truly adapting their business models (42:52) Three practical tips to takeaway from this episode of Lights Out (44:48) Join us at Top Shops 2025 (Get 20% off with code MAK20) Resources & People Mentioned Achieve RASRAM with SMW Autoblok  Join us at Top Shops 2025 (Get 20% off with code MAK20) Investing in your business is an investment in ProShop ERP Connect With Lights Out LinkedIn MakingChips.com Subscribe to Lights Out On Apple and Spotify Audio Production and Show Notes by - PODCAST FAST TRACK

You can collect data all day—but if you're not using it to coach your team, you're missing the point. In this episode of Lights Out, hosts Nick Goellner and Dave Vuyk wrap up their "Mindset Shifts for Lights Out Legends" series with one final transformation: moving from a monitored shop to a coached one. Drawing on lessons from Nick's recent talk at the Automated Shop Conference, the hosts unpack how to turn dashboards into decisions and metrics into motivation. They explain why dashboards don't make chips, how to turn OEE from a vanity metric into a coaching tool, and how to align both machines and people toward a shared goal of improvement. Nick also introduces the idea of the "other OEE"—Overall Employee Engagement—and explores how the best shops connect coaching, culture, and continuous improvement into measurable performance. From building the right tech stack (ERP, MES, and machine monitoring) to running better daily standups, this conversation breaks down what it really takes to lead a high-performance, data-driven manufacturing team. Whether you're running one shift or lights out, this episode will challenge how you think about data, leadership, and what it means to truly coach your people toward operational excellence.  You will want to hear this episode if you are interested in... (0:24) Why Verdant Commercial Capital is a partner in your business (2:50) Highlights from Nick's trip to EMO (and global trends about machine monitoring) (7:30) Recap of previous Lights Out mindset shifts  (8:25) "Dashboards don't make chips" — why data without action is waste (9:14) The difference between a head coach and a head monitor in manufacturing (13:11) How cadenced meetings and daily standups drive accountability (14:30) Why starting manual helps validate processes before investing in tech (15:45) Breaking down ERP, MES, and machine monitoring (and how they work together) (20:33) Check out the SMW Autoblok catalog (21:13) Defining OEE: availability × performance × quality as the shop's north star metric (23:05) Adaptive vs. accelerated performance—why slowing down can speed you up (27:09) What world-class OEE looks like and why most shops start around 20% (29:13) Coaching strategies to improve machine availability and uptime (32:00) How capturing downtime reasons reveals the real improvement opportunities (33:46) Dissecting the other OEE: Overall Employee Engagement (38:09) Turning OEE into a coaching tool rather than a vanity metric (40:12) Football and manufacturing: how coaching and data awareness drive success (42:21) Use Hire MFG Leaders for your next hire Resources & People Mentioned Why Verdant Commercial Capital is a partner in your business Check out the SMW Autoblok catalog Use Hire MFG Leaders for your next hire Connect With Lights Out LinkedIn MakingChips.com Subscribe to Lights Out On Apple and Spotify Audio Production and Show Notes by - PODCAST FAST TRACK

Lights-out manufacturing isn't just about adding robots or running machines overnight — it's about creating a culture and a system where your shop can perform at its peak without constant human intervention. In this episode of Lights Out, hosts Nick Goellner, Eric Nekich, and David Vuyk sit down with innovator and entrepreneur Camoren Schley of Slytek to explore the technologies and mindsets making true lights-out operations possible. Camoren's story begins in his grandfather's Denver manufacturing shop and evolves into a journey of building and selling high-pressure coolant systems, developing machine monitoring technology, and launching Slytek's advanced adaptive control solutions. He's not just creating products—he's redefining how small and mid-sized shops can compete with enterprise-level operations. This episode dives into the mindset shift from being aggressive to adaptive and reactive to predictive—a crucial transformation for any shop looking to scale its production, reduce tool wear, and embrace automation. Camoren explains how adaptive controls, process monitoring, and integrated machine intelligence can help shops run longer, safer, and smarter while dramatically cutting costs. Listeners will also hear real-world examples of shops that implemented Slytek technology to move from constant babysitting and tool breakage to fully unattended overnight production. Whether you're running five machines or 150, this conversation shows how measuring, monitoring, and coaching can unlock the next level of performance. Finally, the hosts discuss how Slytek's holistic approach—from machine monitoring to process control to coaching—bridges the gap between data and decision-making. It's a blueprint for any manufacturer looking to shift from firefighting to future-proofing.  You will want to hear this episode if you are interested in... (0:20) Invest in your business by investing in ProShop ERP (2:48) Why we get to record this episode in person (6:12) Camoren's family manufacturing legacy and how it shaped his approach to problem-solving (8:44) From repairing high-pressure coolant systems to designing his own solutions (11:10) Early machine monitoring experiments and the surprising boost in operator productivity (13:03) Founding Slytek and expanding into tool optimization and adaptive control technology (16:08) Adaptive controls—what they are and why small and mid-size shops need them (17:54) How Slytek's adaptive controls mimic an expert machinist adjusting feed rates in real time (20:23) Shifting from aggressive to adaptive mindsets (A case study on tool breakage) (26:33) Beyond the spindle: Coolant concentration, chip management, and process monitoring (29:37) Grow your top and bottom-line with CliftonLarsonAllen (CLA) (30:35) Slytek's process monitoring in graphite electrode manufacturing (33:43) The "villains" of lights-out manufacturing and how to measure before you manage (38:53) Understanding ROI: tailoring technology to solve the right problem for your shop (43:30) Coaching, accountability, and helping shops turn data into action (46:38) Why Slytek technology is built for small and mid-sized shops as well as big players (48:35) Your Lights Out "Plan of Action" to implement immediately  (53:05) Why you need to listen to Machine Shop Mastery Resources & People Mentioned Invest in your business by investing in ProShop ERP Phoenix Heat Treating Grow your top and bottom-line with CliftonLarsonAllen (CLA) Why you need to listen to Machine Shop Mastery Connect with Camoren Schley Connect on LinkedIn Slytek Connect With Lights Out LinkedIn MakingChips.com Subscribe to Lights Out On Apple and Spotify Audio Production and Show Notes by - PODCAST FAST TRACK

In this episode of Lights Out, Nick Goellner, Eric Nekich, and Dave Vuyk take listeners inside the mindset shifts powering the next wave of lights-out manufacturing. Forget just "working harder" — this conversation is about working smarter, breaking out of fixed thinking, and unlocking massive gains without adding headcount or square footage. The trio opens by sharing the personal routines and disciplines that keep them at peak performance, then pivots to the real topic: transforming machine shops from fixed to mixed mindsets. By rethinking workholding, machine real estate, and cycle times, they reveal how shops can multiply throughput, free up operators, and set the stage for full automation. Drawing on real-world examples — from Swiss shops running uninterrupted for 15 years to small teams like Imago Manufacturing using "time freedom" as a business model — Nick, Eric, and Dave show how modular workholding and extended cycles aren't just efficiency hacks. They're the foundation of the automated mindset that drives profitability, sustainability, and freedom. Whether you run five spindles or fifty, this episode gives you the blueprint to shift your thinking, increase ROI, and build a shop that runs at its best even when you're not there. You will want to hear this episode if you are interested in... (0:28) Invest in your shop by investing in ProShop ERP (3:11) Our morning routines and personal disciplines — how we build leadership habits (6:38) The 3 pillars of health: mental, physical, and spiritual wellness (8:00) How we're building communication and speaking skills (10:34) The five key mindset shifts we're making (11:52) Breaking down fixed vs. mixed mindset (14:47) The ROI of self-centering vises and zero-point systems (19:59) Mixing parts, programs, and setups for longer unattended runs (21:21) Partner with CLA to improve profitability and efficiency (23:05) Change management tips: How to get your team on board (26:00) Lessons from Swiss manufacturing and 15 years of lights-out performance (28:45) Moving from operated to automated: Implementing pallet systems and external setups (31:14) Running a growth experiment starting with our existing machines and vises (33:22) Covering the case study of Feinberg Machining (36:15) Imago Manufacturing: Why we think small shops can win big (39:04) Mega shops vs. networks of high-performing small shops (40:48) Next episode: adaptive vs. aggressive and predictive vs. reactive mindsets (41:20) Listen to the Machine Shop Mastery podcast to level up your shop Resources Mentioned Invest in your shop by investing in ProShop ERP Partner with CLA to improve profitability and efficiency 7 Habits of Highly Effective People Imago Precision Machining's episode of Lights Out Connect With Lights Out LinkedIn MakingChips.com Subscribe to Lights Out On Apple and Spotify Audio Production and Show Notes by - PODCAST FAST TRACK

In this episode of Lights Out, we sit down with a special guest who embodies both tradition and innovation: Yuto Matsuura, fourth-generation leader of Matsuura Machinery. His story is one of legacy, expectation, and transformation—from the weight of inheriting a century-old family business to finding his own passion for manufacturing and automation. We talk openly about the realities of stepping into leadership at a young age. Yuto shares how making a life-changing decision at just fifteen felt more like an obligation than a choice—and how, over time, he turned that responsibility into a genuine calling. His journey, marked by international education, personal turning points, and the influence of his grandfather's legacy, highlights what it really means to steward a family company into the future. From there, we dive into what makes Matsuura unique in the world of automation. Yuto explains why build quality is the foundation of true "lights out" reliability, why five-axis machines aren't just for complex aerospace parts, and why standardization is the hidden key to successful unattended machining. His insights into precision, trust, and process reliability reveal why Matsuura has earned its reputation as one of the world's most respected automation leaders. Yuto opens up about his vision for the next decade—focusing on people, processes, and ERP-driven efficiency in the face of labor shortages. He reflects on what he's most proud of so far, both personally and for the company, and why building relationships has always been at the heart of Matsuura's success. This conversation goes beyond machine tools—it's about carrying a legacy, honoring sacrifice, and shaping the future of manufacturing. You will want to hear this episode if you are interested in... (0:27) Investing in ProShop is an investment in your shop (2:56) Learn about Yuto Matsuura and his family's four-generation legacy (6:26) Making the decision at 15 to commit to Matsuura during Japan's recession (8:43) Feeling obligation versus genuine passion in carrying on the legacy (11:30) Outside expectations—from classmates to relatives—about his future role (13:13) Why his father limited family involvement to one successor (14:44) Yuto's education abroad (earning a master's degree in Canada in one year) (18:38) The influence of his grandfather's legacy and the promise to honor it through work (21:33) Grow your top and bottom line with CLA (23:16) Why Matsuura has become synonymous with automation and precision (27:38) Real-world examples of reliability: Matsuura machines running 15 years straight (30:49) Why five-axis with pallet changers is the foundation of flexible automation (34:28) Standardization as the milestone for successful automation adoption (37:47) Yuto's vision for the next 10–20 years: ERP, processes, and overcoming labor shortages (40:35) Why people and recruiting are as important as technology in manufacturing (41:54) What Yuto is most proud of: dealership networks, global partnerships, and digital transformation (44:26) How online marketing transformed both Matsuura's reach and his own leadership confidence (50:54) "Load the workpiece, push the button, and go home to your family." (51:20) Why you should listen to Machine Shop Mastery  Resources Mentioned Investing in ProShop is an investment in your shop Grow your top and bottom line with CLA Why you should listen to Machine Shop Mastery  Connect with Yuto Matsuura Matsuura Connect on LinkedIn Connect With Lights Out LinkedIn MakingChips.com Subscribe to Lights Out On Apple and Spotify

After three episodes of grit, missteps, and breakthroughs, the story of Iron Clunk Machining comes to its conclusion—and its rebirth as Iron Wheel Manufacturing. This isn't just the end of a narrative—it's proof that the right combination of lean principles, selective automation, and engaged leadership can completely transform a struggling shop into a thriving, joyful workplace. Twelve months after hitting rock bottom, Gary's shop is unrecognizable. A fresh coat of paint and spotless windows signal more than cosmetic changes—they reflect a culture rebuilt from the inside out. Palletized automation, in-process probing, and zero-point clamping now hum alongside a new metric: Overall Employee Engagement (OEEg), tracking continuous improvement efforts and idea adoption. Machines are running at world-class efficiency, but more importantly, people are empowered to innovate every day. With new aerospace and defense certifications in hand, Iron Wheel is no longer chasing low-margin scraps. Selective customer partnerships, a marquee rocket component contract, and lights-out production have created both profitability and peace of mind. Gary can finally take a vacation—confident the team has everything under control. The transformation comes full circle when Iron Wheel is featured as a Top Shop Turnaround, hosting tours to show others the path from chaos to control. As Klaus tells Gary, "Automation isn't a trap—it's freedom." And in this shop, that freedom now fuels not just productivity, but careers, creativity, and culture.  You will want to hear this episode if you are interested in... (0:16) The real-life ROI of ProShop ERP (2:46) Intro to the final episode of The Automation Trap series (3:37) Recap—value stream mapping, bottlenecks, and early 5S changes (6:06) Iron Clunk reborn as Iron Wheel Manufacturing (6:40) Introduction of Overall Equipment Effectiveness (OEE) metric (9:25) How OEE measures availability, performance, and quality of improvement ideas (10:47) Why tracking engagement and continuous improvement matters (12:34) Pairing lean systems with people-driven problem solving (14:00) Lean-first automation that supports flow, not chaos (18:21) From low-margin work to a joyful, profitable workplace (18:49) Grow your top and bottom-line with CLA (19:27) Leadership without micromanagement—ERP, QMS, and machine monitoring (21:27) Building quality into every function of the business (22:58) Eric explains the "Vision, founder, fit" model (24:14) Balancing shop success with personal life and vision (26:34) The role of people in shop transformations—staffing and recruitment (27:31) Full-circle moment—Iron Wheel hosts a Top Shop Turnaround tour (29:15) How long does it take to turn a shop around?  (33:07) Lean Principles + Smart Automation + Engaged People = Your Legacy (35:05) Future Lights Out episodes—practical implementation and tech focus (36:19) Teaser: Yuto Matsuura on automation and lights-out machining (38:50) Why you need to listen to Machine Shop Mastery Resources & People Mentioned The real-life ROI of ProShop ERP Grow your top and bottom-line with CLA The Machine Shop MBA on MakingChips Check out the Machine Shop Mastery podcast Connect With Lights Out LinkedIn MakingChips.com Subscribe to Lights Out On Apple and Spotify Audio Production by - PODCAST FAST TRACK

Welcome back to Lights Out, where we're continuing our deep dive into Iron Clunk's lean transformation—and this one is a turning point. After hitting rock bottom, Gary's found a lifeline in Klaus and the Lean Stream team. But this isn't a charity case—it's an investment. With tools like value stream mapping, theory of constraints, and 5S, Gary and his crew begin diagnosing their real problems: lost travelers, inefficient setups, no in-process inspection, and automation that added more chaos than value. In this episode, you'll hear how Gary starts to regain control—not just of his machines, but of his culture. Tim, Sarah, and the rest of the Lean Stream crew don't just swoop in with answers; they bring structure, empowerment, and a systematic approach to finding flow. Gary's team starts to see themselves not just as operators, but as problem solvers. We also talk about how the right automation, used in the right way, can unlock real ROI. This isn't about throwing tech at the problem—it's about building the systems that help technology thrive. And it all comes back to visibility, strategy, and aligning your team around what truly drives profit. If you've ever felt like your shop was one big mess of potential—this one's for you. You will want to hear this episode if you are interested in... (0:31) Investing in ProShop is investing in your business (2:55) Post-Europe recap, dad life, and terrible accents (4:23) Recap: Gary's glimmer of hope and commitment to lean (5:55) Scene #1: Meet the Lean Stream team (7:37) Tim Woods = the 8 wastes explained (9:20) Acquiring messy shops with potential: the Gary investment thesis (10:35) Scene #2: Value Stream Mapping: identifying and solving bottlenecks (15:02) Shift the focus: it's not just about cycle time (17:00) Deburring in or outside the machine? Depends on your readiness (18:45) Scene #3: Daily standups and 5S in action (20:41) Grow your top and bottom-line with CLA (21:50) Real-world benefits of a clean, organized shop (22:32) Why 5S fails without standardization and sustainability (23:45) Scene #4: Lean automation vision, from inspection to pallets (25:00) In-process inspection integrated into the system (27:25) Flexibility and smarter job switching with pallets (28:07) The tradeoff: spindle utilization vs. quality (29:00) What's the right OEE target for high-mix shops? (29:43) Dinner scene: Linda's back, and so is hope (31:40) Klaus's story reminds Gary he's not alone (32:36) Final scene: A new future for Iron Clunk takes shape (34:07) Vision → Strategy → Tactics: the right order for shop success (35:30) Personalizing lean: what works for your goals (38:19) What kind of pie? (The real debate of the episode) (39:20) Teaser: next time, Gary takes the lead (39:41) Why you should listen to Machine Shop Mastery Resources & People Mentioned Investing in ProShop ERP is investing in your business Episode 12 of Lights Out Lean Process Improvement with Noah Goellner Traction Connect With Lights Out LinkedIn MakingChips.com Subscribe to Lights Out On Apple and Spotify Audio Production and Show Notes by - PODCAST FAST TRACK

In this special episode of Lights Out, we step away from the Automation Trap series for a special episode recorded at Hexagon Live, where the buzz wasn't just about race car simulators—but about revolutionizing shop floor productivity. We sit down with Darren Metherell, Head of Sales for Hexagon's Connected Worker team, to explore how modern manufacturing operations can digitize smarter, faster, and with less friction than ever before. Hexagon may be known for metrology and measurement tech, but as you'll hear in this conversation, they're playing a much bigger role in the factory of the future. Darren shares how Hexagon is helping mid-sized shops unlock value from the equipment and software they already have—without the six-figure consulting bill.  From paperless travelers to real-time dashboards, from tribal knowledge capture to KPI-driven gamification, the Connected Worker platform is all about helping you run a smarter shop, not just a busier one. The conversation hits on the deep-rooted challenges many shops face: communication gaps, generational shifts, underutilized data, and the overwhelming pressure to automate without disrupting flow. But as Darren explains, real solutions start with empathy, integration, and a roadmap—not a rip-and-replace mentality. Whether you're a job shop looking to go paperless or a multi-plant manufacturer chasing lights-out efficiency, this episode sheds light on how digital transformation can be practical, scalable, and ROI-positive from day one. You will want to hear this episode if you are interested in... (0:18) An investment in ProShop is an investment in your business  (2:00) Introducing Darren Metherell and recapping Hexagon Live (5:38) Darren's journey from VCR data collection to connected manufacturing (7:58) Hexagon's dual strategy: direct sales and enabling their channel (9:05) The paperless traveler solution: eliminating 6 inches of paperwork per job (11:30) Mike explains Hill Manufacturing's structure and core challenges (13:16) Tribal knowledge: Collecting data to actually using it for improvement (15:54) Dashboards and real-time visibility and gamifying performance (18:15) Breaking down OEE vs. spindle utilization (21:38) Grow your top and bottom-line with CLA (22:16) More Connected Worker workflows: quality, inventory, audits, training (26:51) How Hexagon tailors solutions to actual pain points (28:52) Capturing tribal knowledge as interactive digital checklists (30:14) Automating more lights-out hours: sensors, cameras, RFID (32:40) Bringing life to legacy equipment through smart retrofitting (34:10 Why time-to-value beats big custom builds every time (35:15) Making this tech accessible to 10-person shops—not just OEMs (36:32) What Darren's most excited about: unlocking value from existing systems (38:44) Mike reflects on buying shops with aging tech—and scaling anyway (39:43) Connected workers = empowered workers = future leaders (40:33) Check out the Machine Shop Mastery Podcast Resources & People Mentioned Hexagon Connected Worker Connect with Darren Metherell Hexagon Connect on LinkedIn Connect With Lights Out LinkedIn MakingChips.com Subscribe to Lights Out On Apple and Spotify Audio Production and Show Notes by - PODCAST FAST TRACK

In this explosive second installment of our manufacturing audio drama, The Automation Trap, we return to the saga of Gary and his struggling shop, Iron Clunk Machining. Desperate to prove himself and catch up to his more successful rival Klaus, Gary dives headfirst into automation—but without the foundational principles that make automation work. The result? A perfect storm of waste, burnout, and broken trust. Through vivid storytelling, the Lights Out team unpacks the brutal consequences of automating without strategy. We see veteran machinists demoted to deburring, quality control falling apart, and a lonely cobot churning out parts no one can use. The shop floor becomes a textbook case of lean gone wrong: overproduction, motion waste, inventory overflow, and worst of all—unused employee creativity. But the story isn't just about failure. It's a hard look at leadership missteps and the redemptive power of collaboration. When Gary finally hits rock bottom, the very competitor he resented—Klaus—offers him a lifeline and a fresh start. Along the way, we explore why lean thinking matters, what value stream mapping really looks like, and how to turn chaos into clarity. If you're leading a shop through automation or scaling up with tight margins, don't miss this episode. It's raw, real, and packed with lessons you can't afford to learn the hard way. You will want to hear this episode if you are interested in... (0:20) Invest in your shop by investing in ProShop ERP (4:07) How the audience is relating to Gary's story (5:23) A breakdown of lean's eight wastes—and how they show up (12:13) The team recaps Gary's struggles (13:54) Scene 1: The cobot goes live, but chaos erupts—flawed parts, angry employees, and mounting delays (19:53) Grow your top and bottom line with CLA (20:33) Scene 2: Deburring, quality, and morale collapse as Gary isolates his team (26:13) Scene 3: Gary's marriage and shop fall apart as his machine monitoring data lies (27:25) Scene 4: Gary misses out on hiring Sarah, who joins Lean Stream instead (30:11) Scene 5: Klaus offers Gary a second chance—if he's willing to commit (34:12) What Gary (and the audience) can learn from pausing to evaluate the real bottlenecks (37:31) Scene 6: Gary begins the process of transformation—with Klaus as a mentor (39:13) Reflections on community, leadership, and what's next for Gary (41:08) Reasons you should listen to Machine Shop Mastery Resources & People Mentioned The 8 Wastes of Lean The Goal Connect With Lights Out LinkedIn MakingChips.com Subscribe to Lights Out On Apple and Spotify Audio Production and Show Notes by - PODCAST FAST TRACK

What happens when a desperate shop owner tries to copy someone else's success—without understanding the system behind it? In this episode of Lights Out, Nick and Kaleb are joined by their friend and workholding expert Eric Nekich to break down the first chapter of a fictional story that might hit a little too close to home.  "The Automation Trap" follows Gary, the stressed-out owner of IronClunk Machining, who's drowning in inefficiency and envy—especially after touring Klaus's pristine, automated, award-winning shop. Gary's heart is in the right place. But what happens when he throws his last dollars at a cobot, lowballs a high-stakes job, and hopes for a miracle? We explore why copying someone else's automation playbook can backfire, how the wrong KPIs (like spindle utilization) can lead you astray, and why automation should never be the first step in a struggling shop. We also dig into red flags around collaborative robots, the danger of skipping process readiness, and the importance of shop culture and team buy-in. Whether you see yourself in Gary or Klaus—or somewhere in between—this episode will challenge your thinking and spark some laughs along the way. This is part one of a story-driven series you won't want to miss.  You will want to hear this episode if you are interested in... (0:18) Invest in your business by investing in ProShop ERP (2:45) Welcoming Eric Nekich back to the show (3:47) Recapping the previous episode (5:24) Dinosaur vises, angry quality guys, and bad vibes (9:01) The real trap: automating before your process is ready (11:19) The Maestro moment: solving quality bottlenecks with automation (16:43) Enter Klaus: the lean legend with smiling operators and Modern Machine Shop awards (18:50) Is your envy even valid? Why copying Klaus might not make sense (20:57) Grow your top and bottom line with CliftonLarsonAllen (21:36) Gary's backstory: loans, burnout, and a desperate dream (25:13) High mix vs. high volume: why the context matters (26:27) Team buy-in, financial transparency, and culture shifts (29:32) Spindle utilization vs. OEE: don't get distracted (33:22) The cobot mistake: throwing money at a process you haven't measured (35:59) Pallet vs. part loading: how to match automation to application (36:54) Cobot myths: it's not collaborative unless the whole setup is (39:10) Cliffhanger: Gary wins the job—but he's not ready to deliver (41:18) What Gary should've done instead: value stream mapping and expert help (45:51) Why you should listen to Machine Shop Mastery Resources & People Mentioned Keys to Maintaining a Manufacturing Leadership Mindset Workholding Evolves with Great Partnerships  The Toyota Way The Goal Connect With Lights Out LinkedIn MakingChips.com Subscribe to Lights Out On Apple and Spotify Audio Production and Show Notes by - PODCAST FAST TRACK

What if going "lights out" wasn't about giant robots or million-dollar cells—but about one simple mindset shift? In this kickoff to our new Automation Academy series, we break down the truth behind successful automation. Spoiler: it's not just about buying a robot. It's about building a stable process, defining standards, and rethinking what's possible in your shop. Whether you're already dabbling in automation or still think it's "not the right fit," this episode is your wake-up call. We get real about the labor gap, international competition, and why automation is no longer optional—it's a matter of survival for shops in North America. Then we get practical. We talk through what automation readiness actually looks like, how to run no-risk simulations, and what most shops get wrong when they rush into technology. If you've ever said, "We're not the kind of shop that can automate," this one's for you. Because the first step to lights-out isn't a machine—it's a decision.  You will want to hear this episode if you are interested in... (0:23) Why investing in ProShop ERP is investing in your business (2:51) Launching the Automation Academy and why it matters (5:58) Breaking the myth: "We're not the right shop for automation" (9:30) Labor cost comparisons and reshoring pressure (12:00) Automation as a path to upskilling, not layoffs (15:17) Mapping your process before automating anything (17:59) Why standardization is the real foundation for automation (19:58) How to simulate lights-out before buying equipment (21:51) How to grow your top and bottom line with CLA (23:01) Monitoring, readiness, and proving ROI from the start (28:59) Managing cultural resistance and getting team buy-in (31:43) Infrastructure checklist: air, power, network, layout (37:34) Why cobots aren't a magic bullet (and what to ask first) (41:00) Wrapping up with key takeaways and what's next in the series (43:10) Why you need to listen to Machine Shop Mastery Connect With Lights Out LinkedIn MakingChips.com Subscribe to Lights Out On Apple and Spotify Audio Production by PODCAST FAST TRACK

What happens when cutting-edge CAM automation meets boots-on-the-ground manufacturing know-how? You get an eye-opening conversation that will challenge the way you think about the future of your shop—and your role in it.  In this episode of Lights Out, we sit down with David Vuyk, a guy who's walked every inch of the shop floor and now finds himself at the forefront of digital manufacturing transformation with CloudNC. But don't expect a tech sales pitch—this is a candid, no-holds-barred look at the human side of automation and why real success hinges on more than just software. If you've ever felt the tension between adopting new technology and keeping your team engaged, this episode is for you. David shares his journey from mechanical designer, to job shop operator, to now driving customer success for bleeding-edge CAM automation.  Along the way, he tackles the tough questions: What happens when programmers fear being replaced? How do you overcome resistance from the shop floor? And why is customer success just as important—if not more—than sales when it comes to scaling disruptive tech? But this isn't just about change management—it's about reimagining what your people can achieve when they're empowered, not threatened, by automation. We dive deep into the mindset shifts that shop owners and frontline leaders need to make to truly go Lights Out. Plus, they reveal why failing to engage your team can lead to churn, wasted tech investments, and missed opportunities for growth. Whether you're a shop owner, an operations leader, or just someone who wants to future-proof your manufacturing business, you'll leave this episode with a fresh perspective on how to turn resistance into results. The message is clear: if you can run lights out, you must run lights out—and it all starts with making your people the heroes of your automation journey.  You will want to hear this episode if you are interested in... (0:47) Why you need to complete the Top Shops benchmarking survey (2:30) David Vuyk's journey from mechanical design to CNC machining to tech solutions (10:31) Navigating resistance on the shop floor and managing change (13:03) Engaging frontline workers and leadership for tech adoption (14:53) Dave's role at CloudNC and how he works with decision-makers (18:45) Elevating employees through automation, not replacing them (22:27) The CloudNC phased approach to customer success (25:04) Grow your top and bottom line with CLA (26:57) The StoryBrand framework: Communicating your company's true value (34:17) Thinking beyond your product: Coaching customers for long-term lights-out success (38:42) Solving constraints beyond your offering (tools, processes, mindsets) (41:23) The responsibility of software teams to simplify adoption (42:16) Our final takeaways from the conversation  (51:37) Check out the Machine Shop Mastery podcast! Resources & People Mentioned Grow your top and bottom-line with CLA Take the Top Shops Survey HIREMfgLeaders.com Storybrand Connect with David Vuyk Connect on LinkedIn CloudNC Connect With Lights Out LinkedIn MakingChips.com Subscribe to Lights Out On Apple and Spotify

Most small manufacturers don't realize they're being quietly supported by one of the most impactful public-private partnerships in the country. The Manufacturing Extension Partnership (MEP) has long been the hidden backbone behind training programs, grant facilitation, process improvements, and critical tech upgrades for shops across the U.S. But recent Federal decisions to defund these programs—without clear communication or reasoning—have sparked confusion and alarm among industry insiders. In this episode, a passionate roundtable of manufacturers and advocates reveals just how deeply the MEPs have shaped their businesses, supported workforce development, and opened doors to opportunity they couldn't have accessed alone. From AR-integrated quoting tools to automation investment guidance, these stories show a clear economic impact that extends far beyond individual shops—right into the health of local communities and the national manufacturing strategy. If you're just hearing about MEPs now, you're not alone—but you are at risk. This conversation lays out what's at stake, why it matters, and what you can do right now to help save a resource that quietly powers tens of thousands of manufacturers nationwide. YouTube: https://youtu.be/WNjevmTNUu4 VideoAsk: https://www.videoask.com/fiyvfkcdd

What if the real sign of a thriving machine shop isn't how hard the lights are on—but how confidently you can turn them off? In this episode of Lights Out, we sit back down with Ryan Bankel of Imago Manufacturing to get into the guts of how a high-performing shop can run with minimal human presence and still crank out quality parts. This isn't about overnight success—it's about obsessing, intelligently and intentionally, over what "lights out" actually takes, from tooling considerations to culture, chip control to checklists. Ryan pulls back the curtain on how he reengineered not just his machines but his mindset. He breaks down the daily "Lights Out Checklist" laminated on every machine, the unsexy decisions that fuel unattended machining, and the radical belief that automation isn't just about more parts—it's about more life. With bourbon in hand and clarity on tap, we get real about boundaries, freedom, and the juice-to-squeeze ratio that drives modern manufacturing forward. Whether you're still tied to the spindle or just starting to imagine what your shop could look like without you in it, this episode offers a blueprint for rethinking everything—from how you spend your hours to how you scale your value. Automation isn't just for the big guys. It's for anyone ready to lead with intention, accountability, and maybe a little help from Bon Jovi. You will want to hear this episode if you are interested in... (00:00) Bourbon, broken phones, and kicking off part two (00:38) Why you should complete the Modern Machine Shop Top Shops Survey (03:10) Why "lights out" isn't just for large shops (04:40) The role of positive constraints in Ryan's business philosophy (08:09) Designing schedules for freedom—not burnout (11:55) Trust and autonomy: the cultural foundation of unattended machining (13:42) The case for decoupling the owner from the day-to-day (15:51) Live tooling, bar feeders, and why Okuma gets the job done (20:05) The Imago Manufacturing Daily Lights Out Checklist (21:38) The must-run-unattended mindset and its ripple effect (25:44) Ryan's "three-day rule" for qualifying lights-out jobs (30:33) Real-world risks: scrap, tool failure, and power loss (33:48) Chip control, part ejection, and machine limitations (36:57) Checklist development from real pain points (41:27) Defining the juice-to-squeeze ratio and scoring process viability (44:09) How to access the Daily Lights Out Checklist + wrap-up (46:15) Check out the Buy the Numbers podcast! Resources & People Mentioned Complete the Modern Machine Shop Top Shops Survey How Ryan named Imago  Connect with Ryan Bankel The Imago Manufacturing Daily Lights Out Checklist Imago Manufacturing  Connect on LinkedIn Connect With Lights Out LinkedIn MakingChips.com Subscribe to Lights Out On Apple and Spotify Audio Production and Show Notes by - PODCAST FAST TRACK

Have you ever felt like the traditional path of working harder to get ahead isn't the answer? In this episode, Ryan Bankel, founder of Imago Precision Machining, shares the story of how he built his business from the ground up.  What started in a garage has grown into a company with a strong focus on sustainability and automation. Ryan talks about how he carefully crafted his shop's operations to run smoothly, even without him being physically present. His goal? Time freedom—not just for himself, but for his employees, too. As a self-taught machinist, Ryan didn't follow the traditional path of learning in a formal setting. Instead, he honed his skills on the job, navigating the challenges of running a business while staying true to his vision.  He reflects on the tough early years, working long hours to make ends meet and building a company that would eventually allow him the flexibility he always dreamed of. Through trial and error, he developed a model that works for him—a model that combines quality, innovation, and a commitment to time freedom. What stands out about Ryan's journey is his approach to business growth. Unlike many entrepreneurs who focus on scaling for the sake of growth, Ryan has embraced a model that values sustainability and keeping the business at a manageable size. Ryan's model prioritizes not just technology and automation, but also a strong shop culture and a sustainable pace of growth, challenging the common belief that bigger is always better. His approach ensures that his shop maintains a strong, close-knit culture, while still embracing modern technologies and automation. Ryan's story is a powerful example of how success doesn't have to mean sacrificing your values or your time. You will want to hear this episode if you are interested in... (0:00) Introduction to Ryan Bankel (0:31) Why you need to take the Modern Machine Shop Top Shop Survey (3:38) Our tour of the Imago shop (including the suave bathroom) (6:53) How we connected with Ryan on LinkedIn (12:13) Ryan's journey into metalworking  (21:59) From running a shop to launching Imago (24:42) The significance of Ryan's decision to keep his shop small (29:30) Bringing in new technology & keeping employees engaged (33:03) What "time freedom" means for Ryan (37:24) Ryan's evolving vision for his business: What's next? (39:11) Stay tuned for part 2 to learn how Ryan runs his business lights out (40:57) Why you need to check out the MakingSparks podcast  Resources & People Mentioned Machine Shop MBA: How to Become a Top Shop Complete the Modern Machine Shop Top Shops Survey Connect with Ryan Bankel Imago Manufacturing  Connect on LinkedIn Connect With Lights Out LinkedIn MakingChips.com Subscribe to Lights Out On Apple and Spotify Audio Production and Show Notes by - PODCAST FAST TRACK

In this episode of Lights Out, we're joined by a true innovator in the manufacturing space, Al Whatmough, CEO of Toolpath. Al brings a wealth of experience from his time at Autodesk and his leadership at Toolpath, where he's driving the next wave of automation in CNC machining. Together, we dive into the revolutionary role that AI is playing in reshaping manufacturing operations, offering fresh perspectives on how automation can enhance productivity and streamline processes on the shop floor. Throughout the conversation, Al unpacks the exciting developments at Toolpath, including their acquisition of Chatter, a key technology that helps shops automate their operations more effectively. He shares his vision for the future of manufacturing, where AI doesn't just automate processes but actively assists in decision-making, freeing up cognitive load for operators and improving workflow efficiency. We also explore the challenges traditional shops face when integrating new technology and how bridging generational gaps in the workforce is crucial for embracing the full potential of automation. This episode is a must-listen for manufacturing leaders looking to understand how AI and automation can create smarter, more agile operations. Al's insights into the real-world applications of AI, along with his thoughtful reflections on industry trends, will inspire you to think differently about the tools you use and the systems you have in place. You'll want to hear this episode if you are interested in... (0:00) Chatting about our time at the MFG Meeting 2025 (3:06) Introducing Al Whatmough, CEO of Toolpath (3:40) Bridging the generational divide in manufacturing (6:20) Al's journey from Autodesk to Toolpath and what they aim to achieve (8:37) Building trust in AI and overcoming skepticism from more traditional shops (11:11) The acquisition of Chatter and how it enhances Toolpath's capabilities (12:39) Why automation should focus on the mundane tasks to free up cognitive load (13:38) The dangers of chasing complex problems rather than solving simple ones (15:52) The importance of understanding customer needs and creating tailored solutions (18:13) The intersection of AI and existing technologies in modern manufacturing (21:24) Rethinking workflows with AI and improving the connection between tools (26:57) Know what you're good at and learn to do it well (33:22) Reflections on the future of AI and automation in manufacturing Connect with Al Whatmough Toolpath Connect on LinkedIn Connect With Lights Out LinkedIn MakingChips.com Audio Production and Show Notes by - PODCAST FAST TRACK

Are robots really taking over human jobs, or is it the other way around? In this eye-opening episode of Lights Out, hosts Nick and Kaleb sit down with automation expert Max Falcone to challenge one of the biggest misconceptions in manufacturing: that automation replaces workers.  Instead, they argue that too many people are still stuck performing tedious, repetitive tasks that should already be automated—tasks that drain productivity, increase injuries, and contribute to worker burnout. With over 23 years of experience in automation, robotics, and material finishing, Max brings a fresh perspective on how manufacturers can rethink their processes. As Vice President of Sales Engineering at PushCorp, he has helped countless shops integrate automation in ways that make businesses more efficient while creating better jobs for skilled workers. In this episode, you'll hear why the right technology can help manufacturers maximize their workforce, eliminate bottlenecks, and improve safety—without sacrificing jobs. Plus, we dig into how manufacturers should be approaching automation today, from understanding the difference between passive and active compliance in robotics to identifying the right tasks to automate. If you're a shop owner, machinist, or anyone in the manufacturing industry looking for ways to optimize operations and stay ahead of the curve, this is an episode you won't want to miss. You will want to hear this episode if you are interested in... (02:00) Flipping the script: Are humans taking robot jobs? (3:00) Max's journey into automation and robotics (12:00) The power of PushCorp (and why it matters) (16:33) Passive vs. active compliance in robotic automation (21:40) How automation can improve safety and efficiency in manufacturing (23:41) Why machine shops should rethink deburring and finishing processes (27:37) The importance of hands-on experience in engineering and manufacturing (31:56) Why the industry needs more problem solvers and skilled workers  Connect with Max Falcone PushCorp Connect on LinkedIn Connect With Lights Out LinkedIn MakingChips.com Subscribe to Lights Out Audio Production and Show Notes by - PODCAST FAST TRACK

What separates the best shops from the crowd? It's not just the technology they use—it's the way they think. The top manufacturing leaders aren't content with operators who say, 'I run a mill,' or 'She programs machines.'  Instead, they cultivate a culture where everyone is focused on one goal: increasing throughput. By aligning your people, resources, and technology to make your business successful, you build a team where nobody is a cog in the wheel—everyone is part of a powerful engine. For years, many in the industry have seen robotics and automation as unnecessary expenses, asking, 'Why invest in a $200,000 robot loading cell when I could just add another spindle?' But what if that mindset is holding your shop back from unlocking its true potential?  By automating tasks like workpiece delivery and machine loading, you free your team to focus on high-value work, maximizing throughput and creating a culture of innovation and growth. We'll also explore what the machine tool dealer of the future looks like, share real-world stories of shops that made the leap into automation, and address common concerns—like how much programming experience your team really needs.  Whether you're looking to inspire your team, adopt cutting-edge technology, or simply break free from outdated mindsets, this episode is packed with actionable advice and fresh perspectives. Tune in now to learn why throughput is more than just a metric—it's a mindset that can transform your business. You will want to hear this episode if you are interested in... (1:54) Get to know Lights Out Co-host Kaleb Mertz  (4:16) Max Rothenhausler's origin story  (10:43) The project that Max and Kaleb are spearheading   (14:52)The importance of automation to career longevity?  (17:04) Why is it easier to work with the end-user instead of the dealer?  (20:22) Overcoming the old-school mentality and adopting automation  (25:56) How much robotic programming experience do you need?  (28:38) What would the machine shop of the future look like?   (31:47) How to structure the machine shop of the future  (33:41) The industry is lacking machinists  (37:30) Take on a new product line—or find partners?  (44:58) Your customer will always be your best salesman  Resources & People Mentioned Business Moves at the Speed of Trust Connect with Max Rothenhausler Connect on LinkedIn 21st Century Machine Tools Connect With Lights Out LinkedIn MakingChips.com Subscribe to Lights Out Audio Production and Show Notes by - PODCAST FAST TRACK

In this episode of Lights Out, Wade Anderson, VP of Engineering and Automation at Okuma delivers a compelling look at how automation is transforming the manufacturing landscape.  Along with Steve DeGrasse, the East Coast Regional Sales Director at Hennig, we uncover why tomorrow's machine tools will require rethinking—like side-door access for robots and integrated pallet delivery systems—and how additive manufacturing and AI will reshape priorities even for small shops aiming to go lights-out.  With a trust-first approach, Wade explains how maximizing a customer's current capabilities builds the foundation for introducing transformative automation solutions. This conversation isn't just about technology—it's about people. We explore how sales strategies, compensation plans, and service roles must evolve to meet the demands of an automation-driven world. Fostering collaboration between sales professionals and engineers is critical for success and how the next generation of talent, raised with robotics, will lead the way.  Packed with real-world insights and forward-thinking strategies, this episode is a must-listen for anyone navigating the future of manufacturing. Don't miss their candid take on what it takes to build trust and drive innovation in a rapidly changing industry. – Nick You will want to hear this episode if you are interested in... Introducing Wade Anderson from Okuma [2:40] Steve's hilarious IMTS Oyster story [8:11]  How do we make machine tools automation friendly? [12:00]  Should we adjust compensation plans for salespeople? [25:00]  How does service need to evolve with automation? [30:50]  Resources & People Mentioned Shop Matters Podcast on YouTube At The Boring Bar #1 Connect with Steve DeGrasse Connect with Wade Anderson Connect on LinkedIn Okuma America Connect With LightsOut LinkedIn MakingChips.com Subscribe to SHOW NAME Audio Production and Show Notes by - PODCAST FAST TRACK

In this episode of Lights Out, we explore how cutting-edge coolant technology is transforming manufacturing by enabling efficiency, stability, and sustainability. Tiffany Bryson and Christopher Porsch of Blaser emphasize the need for a repeatable, reliable process, noting that automation hinges on stable coolant systems.  Scott Cooley, with Hennig, explains how tailored solutions address each customer's specific materials and machining needs, with advanced filtration systems supporting lights-out operations by maintaining a clean, stable environment. Blaser's approach to coolant as a "liquid tool" highlights its importance beyond mere maintenance—coolant is an essential investment in long-term productivity and profitability. Camoren Schley adds that high-pressure systems enhance heat dissipation and extend tool life, further stabilizing production.  This episode dives into how the right coolant technology can solve key challenges, helping manufacturers optimize processes, reduce downtime, and prepare for continuous, efficient production. Don't miss it! You will want to hear this episode if you are interested in... [1:09] Introducing today's special guests  [3:16] Everyone's Day #1 IMTS experience  [4:11] Manufacturing leader spotlight [9:10] Does technology change how you serve customers? [11:54] Understanding the chemistry of coolant [15:52] How high pressure can solve chip accumulation challenges [18:32] What does the term "liquid tool" mean to Blaser? [21:12] The importance of material compatibility [24:24] Reducing the amount of "sludge" created [28:16] How coolant helps with heat dissipation [31:42] What's on the horizon for Blaser, Hennig, and Slytek? [37:09] Why foam control is incredibly important  Resources & People Mentioned Blaser Swisslube Hennig Connect with Tiffany Bryson Connect with Christopher Porsch Connect with Scott Cooley Connect with Camoren Schley Connect With LightsOut LinkedIn MakingChips.com Subscribe to SHOW NAME Audio Production and Show Notes by - PODCAST FAST TRACK

What do you need to know before you launch automation in your shop? What would be signs that you're not ready to automate? If you're launching the process, how can you use your ERP/MRP to the fullest?  Even the smallest mistakes—like not having a process in place to deal with the chips your machines are creating while running lights out—can be costly. We want to help you avoid those costly errors.  That's why Paul Van Metre and Mike Payne join me to tackle the important things you need to consider before you run lights out. Because if you're not MakingChips, you're not making money. BAM! Segments [0:35] Why you need ProShop ERP [5:08] What's new with the crew [6:43] Manufacturing Leadership Spotlight [13:52] Do you have a repeatable process?  [19:03] NetSuite by Oracle [20:31] Do you have a chip management process? [23:48] Cutting tool management features [26:24] Are you making adjustments for accurate costs? [34:06] Do you have training in place for your team?  [37:16] Do you have a preventative maintenance program? Resources mentioned on this episode The Oscar Mike Foundation Noah Currier The Checklist Manifesto NetSuite by Oracle Moseys Production Shop Tour Connect With MakingChips www.MakingChips.com On Facebook On LinkedIn On Instagram On Twitter On YouTube

Here's our controversial take: We believe that "automated" is more important than "operated". It's a stance that scares a lot of operators—but it shouldn't. In this episode of MakingChips, Mike Payne and Kaleb Mertz return to dive into part loading and pallet loading, a mixed vs fixed mindset, and why predictive is better than reactive. We'll connect all of it back to every shop's end goal: business results. Don't miss it! Segments [0:18] Learn about IMTS 2024 Sectors [4:03] Part loading vs pallet loading [9:53] Embrace a mixed vs fixed mindset [16:00] Manufacturing Transformed [17:32] Predictive is better than reactive  [22:29] If you can sense it, you can do it Resources mentioned on this episode IMTS Sectors IMTS Community Go listen to the Manufacturing Transformed podcast Connect With MakingChips www.MakingChips.com On Facebook On LinkedIn On Instagram On Twitter On YouTube

Machine monitoring can give us insights into our machines that can and should change how we're operating. The end goal is to drive better business results. But how should monitoring be paired with advanced business strategies to help you achieve those results? Mike Payne, Kaleb Mertz and I connect the dots in this episode of MakingChips. Because if you're not efficiently MakingChips, you're not making money. BAM!  – Nick Goellner Segments [0:20] Learn more about IMTS 2024 Elevate [2:28] What we listen to at work [7:00] Manufacturing News: Technology Orders Grow [13:08] Latin America Conference at IMTS [15:02] Using ProShop for cutting tool management [16:11] Coaching is more important than monitoring [21:21] Adaptive controls and tooling optimizations  Resources mentioned on this episode IMTS Elevate ChillHop Radio Pop Goes Classical on Spotify Erica Violet on Spotify Manufacturing Technology Orders Grow Despite Sustained High Interest Rates Connect With MakingChips www.MakingChips.com On Facebook On LinkedIn On Instagram On Twitter On YouTube

Can small shops begin to automate their processes? Where do they start with automation? In this episode of MakingChips, the CNC Samurai, Steve Courchane, returns to share his passion for automation. He lays out his 3M process and how it changes the way you view automation. Because if you're not modeling, making, or measuring—you're not MakingChips. And if you're not MakingChips, you're not making money. BAM! – Jason Zenger Segments [0:20] Join the AMT community!  [4:06] Update on my progress!  [5:40] Welcoming Steve Courchane back [7:35] Machine Shop Masterclass [14:53] Manufacturing Leadership Spotlight [19:52] Who is the CNC Samurai?  [23:30] Why branding was important to Steve [26:13] It's time to graduate to NetSuite by Oracle [27:33] How Steve's mindset has changed about automation [34:27] When Steve learned to love automation  [36:37] Steve's 3M process: model, make, and measure Resources mentioned on this episode Join the AMT community!  What the Heck is a Samurai CNC Machinist? Winning the War for Talent by Chris Czarnik Steve Courchane on Instagram Chris Luecke on LinkedIn The Cultish Show NetSuite by Oracle Connect With MakingChips www.MakingChips.com On Facebook On LinkedIn On Instagram On Twitter On YouTube

POV: You've decided to start the process of implementing automation in your machine shop—but it isn't as easy as flipping a switch. It's a process that consists of failing forward and learning from every mistake. Tom Schroeder—the Executive Vice President at PBC Linear—joins us in this episode of Lights Out to share how to prioritize flexibility when you invest in and begin to implement automation in your shop. Because if you're not making the right chips, you're not making money. – Nick Segments [1:28] Learn more about Kaleb Mertz [4:04] Today's guest: Tom Schroeder  [5:16] What's the Chip on Your Shoulder?  [11:44] PBC Linear's investment in an MCM  [16:52] Get NetSuite's KPI Checklist  [19:31] Managing high mix low volume  [23:40] Steps to take before automating  [27:11] Why automation is necessary  [30:00] Innovation = learning to think differently  [32:30] Automation doesn't take away jobs  Resources mentioned on this episode Get your free KPI checklist from NetSuite by Oracle!  Kaleb Mertz on LinkedIn Tom Schroeder on LinkedIn Episode #399: Do We Need More Manufacturing Entrepreneurs? Connect With MakingChips www.MakingChips.com On Facebook On LinkedIn On Instagram On Twitter On YouTube

Are you embracing automation in your shop? Or are you hesitating because you're unsure how to implement it so that you're making the best use of your time and money? Brian Kippen—the owner and CEO of KAD Models & Prototypes—reframes how you can use automation.  In this episode of MakingChips, Brian Kippen, Steve DeGrasse, and I share how you can approach automation from a different perspective. Because if you're not automating efficiently, you're not MakingChips, and if you're not MakingChips, you're not making money. BAM! – Nick Segments [0:15] The Lean Setup Guide from ProShop [1:48] Introducing Brian Kippen and Steve DeGrasse [3:12] What's the Chip on Your Shoulder? [5:30] Brian Kippen's origin story [20:36] How Brian approaches automation differently  [24:28] Running his company like a barbershop [30:21] What Brian looks for in new talent [36:44] How Brian is using automated pallet delivery [41:10] Why Brian took a job as a high school teacher Resources mentioned on this episode The Lean Setup Guide from ProShop Connect with Steve DeGrasse on LinkedIn Connect with Brian Kippen on LinkedIn Connect With MakingChips www.MakingChips.com On Facebook On LinkedIn On Instagram On Twitter On YouTube

Automation continues to be a popular and divisive topic in the manufacturing world. Automation is important for attracting and retaining young talent and growing your business. So we've been working hard to highlight the importance of automation—and where you can dive in—with our Lights Out series.  Chris Luecke—the host of Manufacturing Happy Hour—has a similar goal. We're using our platforms to squash the rumors, lessen fears, and highlight how automation can and will benefit your business. Because if you're not automating, you're not making enough chips, and you're missing out on money. BAM! Segments [0:20] The lean setup guide [2:26] When we embraced automation (and why) [4:03] Manufacturing News: NAM CEO Interview [7:33] Chris's thoughts on our pre-show banter [10:38] How Chris got started in Manufacturing [19:53] Chris's advice to sales management about new projects [22:38] Why automation has become a popular topic [26:07] Is the allure that automation has become more affordable?  [31:00] Automation 101: Where do you start? [34;21] Automation doesn't take people's jobs away [36:40] IT/OT convergence and why it's important [43:25] Chris's assessment of cybersecurity in automation  Resources mentioned on this episode NAM CEO talks on AI, banking, manufacturing, trade relationships, labor market The Manufacturing Happy Hour podcast Connect With MakingChips www.MakingChips.com On Facebook On LinkedIn On Instagram On Twitter On YouTube

Lights out manufacturing isn't only a large topic of conversation but it's also the way of the future. Shops around the world are embracing automation. Are you? If you haven't become part of the automation conversation, don't miss our first lights-out-focused episode with Special guest Titan Gilroy. He shares how automation has progressed, the mindset you need to embrace to be successful, and how to mitigate the risks. Because if you're not automating, you're not MakingChips. And if you're not MakingChips, you're not making money. BAM! – Jason Segments [0:10] The Lean Setup Guide from ProShop [2:08] Manufacturing news: OK, Mexico, Save Me [7:09] How automation technology has progressed  [9:49] The use of robots in automation [11:38] Will robots replace machinists? [15:51] The Industrial Buying Engine with Thomasnet™ [16:23] Check out the Oracle NetSuite ERP [22:57] How to mitigate the risks of lights-out manufacturing  [27:20] If you don't automate, you'll get left behind [28:30] What's next for Titans of CNC and automation? [31:53] How automation is different around the world [36:00] There is a place for everyone in manufacturing Resources mentioned on this episode Lights Out: Training Machinists with an Automation Mindset with Titan Gilroy How Defeat and Success Has Shaped Titan Gilroy, #286 TITANS of CNC Connect with Titan on LinkedIn Get 25% off an annual Thomas™ subscription with code CHIPS25 The Lean Setup Guide from ProShop Connect With MakingChips www.MakingChips.com On Facebook On LinkedIn On Instagram On Twitter On YouTube